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Possibly Welding a rear diff casing...Big fire risk?

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Saffy:
Although it's not as cost effective as a good quick patch, you can get  heavy/standard duty replacement pans which I believe are easier to weld on because there is actually some meat on the edges to weld with.  My series truck has had a pan welding on at some point and it's very good.

Range Rover Blues:
I've had holes a damned site bigger than that in mine (caused by the remains of a diff bearing being left in ther eby a certain well-known LR "specialist") and I've been able to weld it up succesfully.  If there is any oil on the metal you are welding it might not heat up enough to get a good weld but it will thin out and run away well before it reaches it's auto-ignition temp and you shouldn't be getting any sparks inside the alxes casing to light it otherwise.

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